EP1373621B1 - Verfahren und vorrichtung zur herstellung einer verbundplatte mit multiaxialer faserverstärkung - Google Patents

Verfahren und vorrichtung zur herstellung einer verbundplatte mit multiaxialer faserverstärkung Download PDF

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Publication number
EP1373621B1
EP1373621B1 EP02706881A EP02706881A EP1373621B1 EP 1373621 B1 EP1373621 B1 EP 1373621B1 EP 02706881 A EP02706881 A EP 02706881A EP 02706881 A EP02706881 A EP 02706881A EP 1373621 B1 EP1373621 B1 EP 1373621B1
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EP
European Patent Office
Prior art keywords
layer
filaments
yarns
organic material
reinforcement
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP02706881A
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English (en)
French (fr)
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EP1373621A1 (de
Inventor
Dominique Loubinoux
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Saint Gobain Adfors SAS
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Saint Gobain Vetrotex France SA
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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/002—Inorganic yarns or filaments
    • D04H3/004—Glass yarns or filaments
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/105—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by needling
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]

Definitions

  • the invention relates to the production of composite plates with multiaxial fiber reinforcement, and more particularly of composite sheets formed by the association of unidirectional sheets of reinforcing fibers, such as glass fibers, arranged in different directions, and a organic material.
  • One field of application of the invention is the production of composite plates with multiaxial fiber reinforcement intended for the manufacture of moldings made of composite materials, in particular of parts requiring large deformations during molding.
  • the composite plates are usually composed of at least two materials having different melting points, generally a thermoplastic organic matrix material and a reinforcing material embedded within said matrix.
  • the thermoplastic organic material may take on the appearance of a liquid or a solid, such as a powder, a film, a sheet or wires.
  • the reinforcing material may, in turn, be in the form of continuous or cut son, continuous or cut son mat, fabric, grid, ... The choice of the shape and nature of each material to associate depends on the configuration and the final properties of the part to be made.
  • composite sheets are produced by hot pressing of superimposed layers of reinforcement yarns and thermoplastic yarns, the latter of which may be arranged in a warp, weft or both.
  • composite plates are obtained by combining a bundle of parallel threads and a sheet of transversely oriented threads with respect to the direction of the bundle, then subjecting the assembly thus formed to heating followed by cooling.
  • the majority of the yarns are co-mixed yarns made of glass and thermoplastic filaments intimately mixed.
  • the composite plates obtained consist of orthogonal cross-plies (90 °).
  • FR-A-2,743,822 it is proposed to manufacture a composite plate by continuously depositing on a conveyor a fabric of co-mixed yarns of glass filaments and thermoplastic filaments, optionally combined with continuous or cut son. The assembly is then preheated in a hot air oven and then introduced into a "band press" in which it is heated and cooled while being compressed.
  • a band press in which it is heated and cooled while being compressed.
  • the object of the present invention is to propose a process for producing composite plates formed by the combination of a thermoplastic organic material and unidirectional layers of reinforcing threads, in particular made of glass, arranged in different directions, with a view in particular to enabling the production of composite parts of complex shape (for example may comprise ribs connected or not to parts with a small radius of curvature, etc.) and with high relief requiring significant deformation (that is to say large amplitude) of the fibrous structure.
  • the aim of the invention is also to provide homogeneous multiaxial fibrous reinforcing composite plates having a regular orientation of the fibers, which can have a high surface mass (of the order of 500 g / m 2 and up to 1000 to 1500 g / m 2 , or even 3000 g / m 2 ) and whose width can reach 3 meters.
  • Particularly concerned are composite plates with multiaxial fiber reinforcement having a character of symmetry with a principal unidirectional sheet (0 °) located on either side of transverse unidirectional sheets forming opposite angles (- ⁇ / + ⁇ ) by report to senior management.
  • Another object of the invention is to propose a method and a device for implementing this method making it possible to carry out, continuously and in a single step, composite plates with multiaxial fiber reinforcement of variable and relatively high surface density from relatively wide unidirectional layers, without the need to use connecting son.
  • Another object of the invention is to provide a unidirectional sheet comprising co-mixed yarns consisting of reinforcing filaments and thermoplastic filaments, which has sufficient cohesion to be handled, that is to say without the yarns which The compound can be dispersed, but which has a flexibility compatible with the operation of topping.
  • the different steps of the method such as the unidirectional lap, the nappage of the lap, are advantageously continued.
  • plate (as well as “strip”) is meant according to the present invention a thin element relative to its surface, generally plane (but possibly curved) and rigid while retaining the faculty, if any it can be collected and kept in rolled form, preferably on a support having an external diameter greater than 150 mm.
  • it is a solid or substantially solid element, that is to say which has a ratio of the open area to the total area not exceeding 50%.
  • composite is meant according to the present invention the combination of at least two materials of different melting points, generally at least one thermoplastic organic material and at least one reinforcing material, the content of material having the point of the lowest melting point (organic matter) being at least 10% by weight of said combination, and preferably at least 20%.
  • the cohesion is sufficient when the son do not dissociate or little from each other or when there are no defects, including tears, at the time of the lay. In the context of the invention, the cohesion is sufficient when the sheet has a tensile strength in the transverse direction greater than 5 N / 5 cm measured under the conditions of the standard NF EN 29073-3.
  • moving support is meant a conveyor which transfers, from one point to another of a production line, the combination son reinforcement-organic material. Also meant is a unidirectional web of reinforcing son and son of organic material, distinct from each other.
  • the method according to the invention makes it possible to obtain composite plates with multiaxial fiber reinforcement in a single operation, from simple starting structures.
  • the method according to the invention essentially uses unidirectional structures: in particular, the reinforcing material used in the process according to the invention is provided solely in the form of son made cohesive by a mechanical treatment leading to a slight intermingling of filaments that compose them, by a moderate heat treatment or by a suitable chemical treatment, and not incorporated in "complex" structures such as fabrics, assemblies of son held by connecting son, ....
  • the use these simple reinforcement structures in the manufacture of the plates according to the invention has advantages especially in terms of cost and ease of implementation.
  • the method according to the invention makes it possible to directly form a unidirectional sheet having sufficient cohesion but also flexibility to be able to be napped, that is to say to form symmetrically arranged transverse layers compared to the driving direction.
  • the flexibility is assessed in the following manner: by maintaining a sheet horizontally at one end and placing it on the generatrix of a cylinder 10 cm in diameter, the angle is measured that forms with the horizontal the free end of the sheet, on a length of 25 cm. The flexibility is sufficient when the value of the angle is equal to or greater than 70 °.
  • the process is advantageous in that it is possible to vary the angle of the lay-up to a very large extent, for example from 30 to 85.degree., Preferably from 40 to 70.degree. preferred equal to 45 or 60 °, and also that the value of the angle can be easily modified by simple adaptation of the speed of the conveyor, and possibly by varying the width of the web deposited transversely if it is desired that the mass surface area of the son-reinforcement-organic material remains constant.
  • the method according to the invention is particularly fast and economical, in particular because it makes it possible to continuously obtain the desired plates directly from wires, by eliminating the transfers from one installation to another as well as the storage of intermediate structures (webs, fabrics, grids).
  • the yarns forming part of the unidirectional web consist of at least 50% of them of co-mingled yarns. consisting of reinforcing filaments and intimately mixed organic material filaments (for example, as described in EP-A-0 599 695 and EP-A-0 616 055 ).
  • the web comprises at least 80% by weight, and particularly preferably 100% by weight of co-mingled yarns.
  • the reinforcing material is generally selected from materials commonly used for strengthening organic materials, such as glass, carbon, aramid, ceramics and plant fibers, for example flax, sisal or hemp, or may be broadly understood as a material of melting point or degradation higher than that of the aforementioned organic material.
  • the glass is chosen.
  • the organic material is for example polyethylene, polypropylene, polyethylene terephthalate, polybutylene terephthalate, phenylene polysulfide, a polymer chosen from polyamides and thermoplastic polyesters, or any other organic material with a thermoplastic nature.
  • the yarns of the unidirectional web are chosen so that the content of organic material in the composite plate is at least 10% by weight and the content of reinforcing material is between 20 and 90% by weight. preferably between 30 and 85% and particularly preferably between 40 and 80%.
  • the unidirectional web may comprise in part son consisting of one of the materials and partly of son made of the other material, these son then being arranged alternately in the web.
  • the son of the unidirectional sheet are most often derived from one or more supports (for example coils supported by one or more creels) or coils (for example bundles) on which they are wound .
  • the step consisting in giving the unidirectional sheet cohesion sufficient to make it suitable for being coated must contribute to preserving the integrity of the reinforcing filaments so that they fulfill the reinforcement function assigned to them. This step can be done in many ways.
  • the cohesion of the ply can be conferred by a slight entanglement of the filaments constituting the threads by a moderate needling or by exposure to a jet of water under pressure.
  • a moderate needling any suitable device may be used, for example a support provided with needles with a vertical reciprocating motion that penetrates through the entire thickness of the web causing a transverse intermingling of the filaments.
  • Entanglement by exposure to a water jet under pressure can be implemented by projecting the water on the sheet disposed on a perforated support or passing over a metal carpet and the jets of water bouncing on the carpets performing a moderate intermingling of threads.
  • the cohesive filaments are made by a moderate heat treatment, at a temperature close to the melting temperature of the organic material. It is important that the fusion of the son is done on the surface, that is to say on a small thickness, so that the sheet maintains a flexibility compatible with the subsequent coating. In general, it operates at a temperature of a few degrees Celsius and up to 15 ° C at the melting temperature of said organic material.
  • This variant is particularly suitable when the son are close to each other, for example at a distance of less than 0.2 mm, the fusion then making it possible to bond the son by contact.
  • the heat treatment may be carried out by any suitable heating means, for example heated rolls, an irradiation device such as an infrared radiation device (oven, lamp (s), panel (s)) and / or one or several devices for blowing hot air (convection hot air oven).
  • an irradiation device such as an infrared radiation device (oven, lamp (s), panel (s)) and / or one or several devices for blowing hot air (convection hot air oven).
  • the cohesion of the sheet may be obtained by providing a chemical material having adhesive properties with respect to the son.
  • This material may be liquid or solid, for example a powder, a film or a web of a material. Materials which develop their hot tack properties (or heat-bonding) are preferred.
  • the heat-sealing material is compatible with the organic material of the yarns and generally the two materials are identical. Polyolefins, and more particularly polypropylene, are preferred.
  • the heat-sealing material is deposited in the form of a web, or a film, the latter advantageously comprising at least one additional layer of organic material of the same nature as that of the yarns, preferably also in the form of fibers or of filaments.
  • the tacky material can be deposited by spraying or spraying when it is in liquid or powder form, and by application of the film or sail followed by heating, preferably under compression, for example between the rolls of a calender.
  • This variant makes it possible to bind wires that are relatively distant uhs from others, up to about 1 cm away.
  • the association of unidirectional sheets within the composite plate with multiaxial fibrous reinforcement can be done in several ways.
  • the unidirectional sheet is coated transversely on a conveyor.
  • a biaxially fibrous reinforcing ply is formed consisting of unidirectional transverse plies whose directions make angles - ⁇ and + ⁇ with the direction of movement (0 °).
  • the unidirectional sheet is laid transversely on a main unidirectional sheet, itself deposited on a conveyor, and composed of reinforcing son and son of organic material.
  • a triaxial fibrous reinforcing ply is formed consisting of unidirectional transverse plies whose directions make angles - ⁇ and + ⁇ with the direction of the main unidirectional ply (0 °).
  • the combination of reinforcement-organic material son passes under at least one zone where it is heated to a temperature between the melting points or degradation materials constituting the combination, this temperature being also lower than the degradation temperature of the material having the lowest melting point.
  • the degradation temperature here refers to the minimum temperature at which a decomposition of the molecules constituting the material (as traditionally defined and understood by those skilled in the art) or an undesirable alteration of the material (for example an inflammation) is observed. , a loss of integrity resulting in a flow of material out of the web) or an undesirable color (eg yellowing).
  • the reinforcing son-organic material combination is heated sufficiently to allow at least a portion of the yarns to bond to one another via the organic material after heating and / or compression, and in most cases cases to enable a substantially solid structure to be obtained.
  • the heating temperature can be of the order of 190 to 230 ° C. when the sheet of threads consists of glass and polypropylene, the order of 280 to 310 ° C when the sheet is made of glass and polyethylene terephthalate and of the order of 270 to 280-290 ° C when the sheet of son is made of glass and polybutylene terephthalate.
  • the heating of the combination of reinforcing son-organic material can be achieved in different ways, for example using a double-band laminating machine, or with the help of heated rollers or a irradiation device such as an infrared radiation device (for example by means of an oven, lamp (s), panel (s)) and / or at least one hot air blowing device (for example forced convection hot air oven).
  • a irradiation device such as an infrared radiation device (for example by means of an oven, lamp (s), panel (s)) and / or at least one hot air blowing device (for example forced convection hot air oven).
  • the heating may be sufficient to allow the binding of the reinforcing son-organic material via the molten organic material (heat setting).
  • the heated combination is further subjected to compression which can be effected by means of one or more two-roll calender, the force exerted on the combination being generally several daN / cm or even several tens daN / cm.
  • the pressure exerted in the compression device compacts the sheet of threads and makes it possible to obtain a homogeneous distribution of the molten thermoplastic material, the structure obtained being frozen by cooling and the cooling being able to take place, at least in part, simultaneously with the compression or can also be performed after a heat compression step.
  • the compression device may comprise or consist of a belt press, for example provided with PTFE coated steel, glass cloth or aramid webs, which comprises a hot zone followed by a cold zone.
  • Cooling can be done in the compression device, for example in a cold shell, or can be done outside the compression device, for example by natural or forced convection.
  • the composite strip after compression and cooling, can be wound on a mandrel of diameter adapted to the characteristics of the band or can be cut into plates for example using a cutter or a circular saw.
  • the present method although described with regard to the layering of a single unidirectional web, can obviously be applied to the web of several webs in the same manner as previously described. It is also possible to insert between the plies at least one unidirectional sheet comprising reinforcing son associated or not with organic material, in a chain, to form plates of greater thickness.
  • the limit in terms of thickness depends essentially on the capacity of the heating device of the reinforcing son-organic material group to compact the sheet to obtain a plate according to the invention.
  • the present invention also relates to a device for implementing the method.
  • This device comprises a conveyor, at least one son feeding device, means making it possible to cohesive a sheet of yarn comprising co-mixed yarns, at least one device for transversely laying a sheet of yarn on said conveyor, at least one heating device of the organic material-reinforcing son assembly and at least one cooling device of said assembly.
  • the device according to the invention may further comprise at least one compression device of said assembly and / or at least one cutting device and / or at least one device for collecting composite plates.
  • the cooling device may be a compression device separate from the cooling device or consist of a single device providing both compression and cooling functions.
  • the composite sheets obtained thanks to the combination of steps of the process according to the invention are, because of their multiaxial structure, perfectly adapted to the production of composite material parts by the molding and thermoforming processes.
  • the plates according to the invention are remarkable that the different plies are not bonded together and that the son are free to move relative to each other. It is therefore possible to obtain parts that have significant deformations and / or reliefs in the direction transverse to the direction of movement (0 °) when the reinforced plates are of the triaxial type (stack 0 ° / - ⁇ / + ⁇ or 0 ° / ⁇ / + ⁇ / 0 °) and also in other directions when the plates are of the biaxial type (- ⁇ / + ⁇ ).
  • the composite sheets obtained have a thickness generally of between a few tenths of a mm and about 2 mm, are rigid, easy to cut and have good mechanical properties. In addition, they have a good surface condition due in particular to the lack of interweaving of the son which results in low shrinkage. It is possible to improve the appearance of the plate by depositing one or more films of a material fulfilling the required function on at least one of the outer faces of the reinforcement-organic material son assembly before the ultimate heating step. to form the plate.
  • the figure 1 discloses a method of manufacturing a composite plate with biaxial fibrous reinforcement (- ⁇ / - ⁇ ) in its simplest embodiment.
  • the wires 1 coming from a beam 2 pass between the teeth of a comb 3 which keep them parallel until they enter a needling device 4 where they are interconnected to form a unidirectional sheet 5.
  • the sheet 5 is deposited on a conveyor 6 in motion by means of a lapping device (spreader-lapper) 7 moving transversely to the direction of movement of the conveyor in a reciprocating motion to form a sheet with biaxial fibrous reinforcement 8 whose directions form with that of the displacement of opposite angles.
  • a lapping device preader-lapper
  • the biaxial sheet 8 then passes between the continuous strips 9 (made of glass cloth impregnated with polytetrafluoroethylene - PTFE -) of a flat laminating press 10.
  • This press comprises a heating zone 11, pressing cylinders 12 which compress the molten thermoplastic material (pressure of the order of 10-20 N / cm 2 and a zone 13 cooled by a circulation of water.
  • the composite band with biaxial fibrous reinforcement obtained at the outlet of the press 10 is then cut continuously by means of the blades 14 and an automatic shear (not represented) into several plates 15.
  • the process of figure 2 discloses a method of manufacturing a triaxial fibrous reinforcing plate using a biaxial fibrous reinforcing ply (- ⁇ / - ⁇ ) and a unidirectional layer arranged in a chain (0 °).
  • a ply 5 is formed from the wires 1 of the beam 2 which are guided by the comb 3 towards the needling device 4.
  • the ply 5 is deposited by means of the layering device 7 on a unidirectional sheet 16 supported by the conveyor 6, the web 16 being constituted here by the son unwound from the beam 17 held parallel with the aid of the comb 18.
  • the association of the layers 19 passes, as in the process of the figure 1 in the press 10 where it is heated in the zone 11, compressed between the rollers 12 and cooled in the zone 13.
  • the composite strip obtained is then wound on the support 20 in rotation.
  • the figure 3 schematically describes a process for manufacturing a composite plate with a triaxial fibrous reinforcement in which the coated yarns (- ⁇ / - ⁇ ) are held between two unidirectional layers arranged in a chain (0 °).
  • the sheet intended to be coated is formed from the son 1 from a beam 2, these son passing on a comb 3 to keep them parallel.
  • the wires are then introduced into a heated device 26 which fixes them in a ply 27 which is coated with the aid of the device 7 between the plies 16 and 21.
  • the composite strip obtained has a homogeneous appearance which can be improved by depositing a polymer film compatible with the organic material of the son on one or the other of his faces or both at the same time.
  • two polypropylene films 28 and 29 are deposited on either side of the association of webs between the strips 9 of the press 10.
  • a composite plate is produced under the conditions of the process of the figure 1 modified in that an additional unidirectional sheet is deposited on the biaxial glass reinforcing sheet (as indicated in FIG. figure 3 , web 21).
  • a unidirectional sheet of 20 cm wide (2.2 threads / cm) is formed.
  • the yarns are rovings of linear density equal to 1870 tex, obtained by co-blending glass filaments (60% by weight, diameter: 18.5 ⁇ m) and polypropylene filaments (40% by weight; diameter: 20 ⁇ m).
  • the web is driven at a speed of 0.48 m / min in the needling 4 1 m wide equipped with 4000 needles (reference: 15x18x32 3.5RB30A 06/15) and set for a penetration of 20 mm and 200 strokes / min, 140 shots / cm 2 .
  • the sheet At the exit of the needling, the sheet has a width of 30 cm and a basis weight of 275 g / m 2 .
  • the needle ply is then deposited on the driven conveyor by means of the lapper 7, the lapping being deposited alternately in opposite directions (+ 76 ° and -76 ° respectively) with respect to the direction of removal (0). °) and each portion of web deposited in a direction not covering the neighboring parts oriented in the same direction.
  • the unidirectional sheet 21, chain, 60 cm wide composed of co-mingled son of the same nature as those constituting the needled mat.
  • the assembly formed then passes into the press 10 in which it is heated (220 ° C) and then cooled (60 ° C) while being compressed (2 bar).
  • the composite plate has a basis weight equal to 825 g / m 2 and has, in the 0 ° direction, a flexural breaking stress equal to 180 MPa, a flexural modulus equal to 12 GPa and a shock absorption energy (Charpy) equal to 85 kJ / m 2 .
  • a composite plate is made using a method according to the figure 3 modified in that the heating device 26 is replaced by a needling device 4.
  • first creel located in the extension of the conveyor, upstream of the latter, there are 330 coils of rovings of the same nature as those described in Example 1.
  • the rovings are also distributed on two combs (0.75 tooth / cm ), to form two identical unidirectional sheets of 2.15 m wide and 140 g / m 2 of mass per unit area.
  • the first ply 16 is deposited directly on the conveyor (speed: 1.5 m / min) and the second ply 21 is deposited downstream of the lapper.
  • Cables (rovings) of the same nature as those described in Example 1 are placed on a second creel.
  • the rovings are placed between the teeth of a comb (2.2 teeth / cm) to form a unidirectional sheet (width: 1.68 m, surface mass: 410 g / m 2 ) which is directed towards the needling machine 4 (width: 3 m, speed: 2.5 m / min, 1000 cpm).
  • the needle ply 5 (width: 2.5 m) is conveyed to the lapper 7, which deposits it alternately at + 60 ° and -60 ° angles, over a width of 2.15 m, onto the first unidirectional sheet carried by the conveyor.
  • the second unidirectional sheet 21 Downstream of the lapper, the second unidirectional sheet 21 is deposited from the first creel.
  • the association of the biaxial ply and the two unidirectional plies is then directed towards the press 10 in a first heated zone (220 ° C., length: 2.2 m), a calender 300 mm in diameter (pressure: 2 bar). and a second cooling zone (10 ° C, length: 2.3 m).
  • a composite triaxial glass reinforcing plate (stack 0 ° / -60 ° / + 60 ° / 0 °) of about 0.6 mm thickness, with a surface density of 830 g / m 2 is obtained which is either coiled, or cut into rectangular plates by means of an automatically controlled shear.
  • Example 2 The procedure is as in Example 2 modified in that the first creel comprises 660 coils of rovings separated into identical layers (comb: 1.5 tooth / cm, weight per unit area: 280 g / m 2 )
  • the resulting composite plate has a thickness of about 0.75 mm and a basis weight of 1110 g / m 2 .
  • a composite plate is produced under the conditions of Example 2.
  • 370 rovings of the same nature as those described in Example 1 are placed on a creel.
  • the rovings are placed between the teeth of a comb (2.2 teeth / cm) to form a unidirectional sheet (width: 1 68 m, weight per unit area 410 g / m 2 ) which is directed to the needling machine 4 (width: 3 m, speed: 2.5 m / min, 1000 rpm).
  • the needle ply 5 (width: 2.5 m) is conveyed to the lapper 7, which deposits it alternately at angles of + 45 ° and -45 °, over a width of 1.25 m on the conveyor (speed: 2, 5 m / min).
  • the association of the layers is directed towards the press 10 in a first heated zone (220 ° C., length: 2.2 m), a calender 300 mm in diameter (pressure: 2 bar) and a second cooling zone (10 ° C, length: 2.3 m).
  • the formed composite plate has a basis weight of 650 g / m 2 .
  • a composite plate is produced by implementing the method described in the figure 3 .
  • the rovings are distributed over two combs (0.75 tooth / cm) so as to form two identical unidirectional sheets 16 and 21 of 2.15 m wide and 140 g / m 2 of mass per unit area.
  • the first ply 16 is deposited directly on the conveyor (speed: 1.5 m / min) and the second ply 21 is deposited downstream of the lapper.
  • a second creel On a second creel are placed 370 coils of rovings of the same nature as those of the first creel and the rovings are distributed between the teeth of a comb (1.5 tooth / cm) to form a unidirectional sheet (width: 2.5 m: basis weight: 280 g / m 2 ).
  • This web is associated with a fibrous web comprising a layer of polypropylene in the form of fibers (weight per unit area: 30 g / m 2 ) and a heat-sealing layer based on a polyolefin in the form of fibers (weight per unit area: 30 g / m 2 ), this last layer being directed towards the sheet.
  • the tablecloth-sail combination passes in the gap of a pair of rollers pressers heated to 140 ° C and then to the lapper 7 which deposits it at angles of + 60 ° and -60 °, over a width of 2.15 m on the first unidirectional sheet carried by the conveyor.
  • the second unidirectional sheet 21 from the first creel is directed to the press 10 consisting successively of a heated zone (220 ° C., length: 2.2 m), a calender of 300 mm diameter (pressure: 2 bar) and a cooling zone (10 ° C, length: 2.3 m).
  • a composite plate approximately 0.6 mm thick and with a surface density of 900 g / m 2 is obtained.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Reinforced Plastic Materials (AREA)

Claims (17)

  1. Verfahren zur Herstellung einer Verbundplatte mit multiaxialer Faserverstärkung, das die Schritte umfaßt, die darin bestehen:
    - eine unidirektionale Lage aus Verstärkungsfäden auszubilden, von denen wenigstens 50 Gew.-% vermischte Fäden sind, die von innig miteinander vermischten Verstärkungsfilamenten und Filamenten aus einem organischen Material gebildet sind
    - der Lage eine Kohäsion zu verleihen, die ihr ermöglicht, aufgelegt zu werden,
    - diese Lage auf einem in Bewegung befindlichen Träger in einer zur Richtung der Bewegung querverlaufenden Richtung, in einer Hin- und Herbewegung mit einem vorgegebenem Ausschlag aufzulegen, wobei die Lage bei jedem Richtungswechsel gewendet wird
    - die sich in Bewegungsrichtung bewegende Einheit aus Verstärkungsfäden und organischem Material zu erhitzen und sie durch die Wirkung der Wärme zu fixieren, eventuell unter Anwendung eines Druckes, sie anschließend abzukühlen, um eine Verbundbahn zu bilden, und
    - die Bahn in Form einer oder mehrerer Verbundplatten zu sammeln.
  2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß der Träger eine Fördereinrichtung ist.
  3. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß der Träger eine unidirektionale Lage aus Glasfasern ist, von denen wenigstens ein Teil vermischte Fäden sind, die von Glasfilamenten und von Filamenten aus einem thermoplastischen organischen Material gebildet sind.
  4. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß die Verstärkungsfilamente Glasfilamente sind.
  5. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, daß die unidirektionale Lage ausschließlich aus vermischten Fäden besteht, die hauptsächlich von Glasfilamenten sowie von Filamenten aus thermoplastischem organischem Material gebildet sind.
  6. Verfahren nach Anspruch 5, dadurch gekennzeichnet, daß die Fäden wenigstens 20 % Glas aufweisen.
  7. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, daß der Lage dadurch Kohäsion verliehen wird, daß sie genadelt oder einem Druckwasserstrahl ausgesetzt wird.
  8. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, daß der Lage durch eine gemäßigte Wärmebehandlung Kohäsion verliehen wird.
  9. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, daß der Lage durch Zuführen eines Haftmaterials Kohäsion verliehen wird.
  10. Verfahren nach Anspruch 9, dadurch gekennzeichnet, daß das Material in Form eines Pulvers, eines Schleiers oder eines Films vorliegt.
  11. Verfahren nach einem der Ansprüche 1 bis 10, dadurch gekennzeichnet, daß die Lage mittels einer Ausbreit- und Legemaschine auf den Träger aufgebracht wird.
  12. Verfahren nach einem der Ansprüche 1 bis 11, dadurch gekennzeichnet, daß wenigstens eine unidirektionale Lage aus vermischten Fäden bestehend aus innig miteinander vermischten Verstärkungsfilamenten und Filamenten aus einem organischen Material auf die quer aufgelegte Lage aufgelegt wird, bevor das Erhitzen der Einheit aus Verstärkungsfäden und organischem Material vollzogen wird.
  13. Verfahren nach Anspruch 12, dadurch gekennzeichnet, daß das Verstärkungsmaterial Glas ist und daß das organische Material thermoplastisch ist.
  14. Vorrichtung für die Durchführung des Verfahrens nach einem der Ansprüche 1 bis 13, umfassend eine Fördereinrichtung, wenigstens eine Fadenzuführvorrichtung, Mittel, die ermöglichen, einer vermischte Fäden aufweisenden Fadenlage Kohäsion zu verleihen, wenigstens eine Vorrichtung, die ermöglicht, eine Fadenlage auf der Fördereinrichtung quer aufzulegen, wenigstens eine Vorrichtung zum Erhitzen der Einheit aus Verstärkungsfäden und organischem Material sowie wenigstens eine Vorrichtung zum Abkühlen der genannten Einheit.
  15. Vorrichtung nach Anspruch 14, dadurch gekennzeichnet, daß sie ferner wenigstens eine Vorrichtung zum Verdichten der Einheit und/oder wenigstens eine Schneidevorrichtung und/oder wenigstens eine Vorrichtung zum Sammeln der Verbundplatten umfaßt.
  16. Vorrichtung nach einem der Ansprüche 14 oder 15, dadurch gekennzeichnet, daß die Mittel, die ermöglichen, der Lage Kohäsion zu verleihen, aus einer Nadelungsvorrichtung oder einer Vorrichtung zum Spritzen von Druckwasserstrahlen, einer Heizvorrichtung oder einer das Zuführen eines Haftmaterials ermöglichenden Vorrichtung bestehen.
  17. Vorrichtung nach einem der Ansprüche 14 bis 16, dadurch gekennzeichnet, daß die Vorrichtung zum Auflegen der Lage eine Ausbreit- und Legemaschine ist.
EP02706881A 2001-03-01 2002-02-20 Verfahren und vorrichtung zur herstellung einer verbundplatte mit multiaxialer faserverstärkung Expired - Lifetime EP1373621B1 (de)

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FR0102837 2001-03-01
FR0102837A FR2821631B1 (fr) 2001-03-01 2001-03-01 Procede et dispositif de fabrication d'une plaque composite a renfort fibreux multiaxial
PCT/FR2002/000636 WO2002070806A1 (fr) 2001-03-01 2002-02-20 Procede et dispositif de fabrication d'une plaque composite a renfort fibreux multiaxial

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CN1507510A (zh) 2004-06-23
US7226518B2 (en) 2007-06-05
EP1373621A1 (de) 2004-01-02
FR2821631B1 (fr) 2003-09-19
MXPA03007803A (es) 2003-12-08
KR20040025666A (ko) 2004-03-24
PL363882A1 (en) 2004-11-29
DE60230597D1 (de) 2009-02-12
US20040082244A1 (en) 2004-04-29
ATE419418T1 (de) 2009-01-15
BR0207763A (pt) 2004-06-01
FR2821631A1 (fr) 2002-09-06
WO2002070806A1 (fr) 2002-09-12
CZ20032358A3 (cs) 2004-04-14
JP2004530053A (ja) 2004-09-30
CA2450672A1 (fr) 2002-09-12
SK10842003A3 (sk) 2004-04-06
AU2002241047B2 (en) 2005-11-17

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